Formaldehyde free binder and multi-component nanoparticle

Abstract

This patent describes formaldehyde free or formaldehyde reduced binders useful, for example, in a fiber based composite material such as glass or other mineral fiber insulation, non-woven fabric or wood-based board. In one example, melamine is used as an acidic solution or a salt. The salt or solution is used to create an aqueous binder with other components such as a polyol and a crosslinker. A preferred polyol is a nanoparticle comprising high molecular weight starch. In other examples, binders include mixtures of a polyol with urea and a crosslinker. In other examples, a multi-component nanoparticle is made by reacting a polyol such as starch in an extruder with an insolubilizer such as melamine or urea. The resulting particles are mixed with water, optionally with other components such as an additional crosslinker, to create an aqueous binder.